EP0435627A2 - Katalysator auf Träger für Olefinpolymerisation - Google Patents

Katalysator auf Träger für Olefinpolymerisation Download PDF

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EP0435627A2
EP0435627A2 EP90314182A EP90314182A EP0435627A2 EP 0435627 A2 EP0435627 A2 EP 0435627A2 EP 90314182 A EP90314182 A EP 90314182A EP 90314182 A EP90314182 A EP 90314182A EP 0435627 A2 EP0435627 A2 EP 0435627A2
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catalyst according
iii
catalyst
compound
transition metal
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EP0435627A3 (en
EP0435627B1 (de
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Robert Olds Haggerty
Per Kristian Husby
Yuri Viktorovich Kissin
Thomas Edward Nowlin
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ExxonMobil Oil Corp
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Mobil Oil Corp
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond

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  • the present invention relates to supported olefin polymerization catalyst and to a method for polymerizing olefins, particularly alpha-olefins, using such a catalyst, and to a method of making such a catalyst.
  • the present invention relates to a catalyst, and a method for preparation thereof, which produces linear low density polyethylene (LLDPE) having a substantially improved compositional homogeneity.
  • LLDPE linear low density polyethylene
  • Linear low density polyethylene polymers possess properties which distinguish them from other polyethylene polymers, such as homopolymers of polyethylene. Certain of these properties are described in US-A-4,076,698.
  • US-A-4,302,566, describes a process for producing linear low density polyethylene polymers in a gas phase, fluid bed reactor.
  • US-A-4,173,547 describes a supported catalyst obtained by treating a support with both an organoaluminum compound and an organomagnesium compound followed by contacting the treated support with a tetravalent titanium compound.
  • US-A-3,787,384, and US-A-4,148,754 describe a catalyst prepared by first reacting a support (e.g., silica containing reactive hydroxyl groups) with an organomagnesium compound (e.g., a Grignard reagent) and then combining the support with a tetravalent titanium compound.
  • a support e.g., silica containing reactive hydroxyl groups
  • an organomagnesium compound e.g., a Grignard reagent
  • US-A-4,063,009 describes a catalyst which is the reaction product of an organomagnesium compound (e.g., an alkylmagnesium halide) with a tetravalent titanium compound.
  • an organomagnesium compound e.g., an alkylmagnesium halide
  • the reaction of the organomagnesium compound with the tetravalent titanium compound takes place in the absence of a support material.
  • US-A-4,481,301 discloses a supported alpha-olefin polymerization catalyst composition prepared by reacting a support containing OH groups with a stoichiometric excess of an organomagnesium composition, with respect to the OH groups content, and then reacting the product with a tetravalent titanium compound.
  • US-A-4,378,304 and US-A-4,458,058 disclose an olefin polymerization catalyst composition synthesized by sequentially reacting: (1) a porous support with a Group IIA organometallic compound, e.g., a dialkylmagnesium; (2) the product of (1) with water or a hydrocarbyl alcohol, e.g., methanol; (3) the product of (2) with a transition metal compound or compounds.
  • the product of the synthesis reaction is activated with a co-catalyst which is a Group IA, IIa, IIIA and/or IIB organometallic compound, including hydrogen.
  • Suitable co-catalysts are n-butylithium, diethylmagnesium, triisobutylaluminum and diethylaluminum chloride.
  • Some of the catalyst compositions of Best also include an acyl halide (US-A-4579835, US-A-4558025) and/or a Group IIIA hydrocarbon halides, such as boron and aluminum dihalides (US-A-4558025).
  • US-A-4,849,389 and US-A-4,833,111 disclose catalyst compositions for polymerizing alpha-olefins which are very active and exhibit very good higher alpha-olefins (C3-C10) incorporation properties.
  • the catalyst of US-A-4833111 is synthesized by reacting, sequentially, a slurry of a solid catalyst carrier, e.g., silica, with a dialkyl organomagnesium composition, a hydroxyl group containing compound, e.g., an alcohol, and at least one transition metal compound.
  • the non-polar solvent is removed to produce a dry-flowing powder, which is activated with trimethylaluminum.
  • the catalyst of US-A-4833111 is synthesized in a manner similar to that of US-A-4849389, except that a halogenated alkyl aluminum compound, e.g., ethyl aluminum dichloride, is used in the synthesis after the slurry is reacted with the transition metal compound.
  • a halogenated alkyl aluminum compound e.g., ethyl aluminum dichloride
  • the olefin copolymers e.g., ethylene/C3-C10 copolymers produced with Ziegler-Natta catalysts, including prior art catalysts, have a relatively broad distribution of side branches. If such copolymers are subject to fractionation, different fractions have widely different levels of branching, indicating that different fractions of the copolymers have different compositions, i.e., they contain varying amounts of ethylene and higher comonomers. US-A-3,645,992 teaches that this broad branching distribution (also referred to by Elston as heterogeneity of the copolymers) is detrimental to the mechanical properties of the copolymers. It is therefore desirable to produce copolymers having improved, more narrow branching distribution of side branches.
  • olefins e.g., alpha-olefins
  • a supported alpha-olefin polymerization catalyst composition of this invention also referred to herein as a catalyst precursor, is prepared in a method comprising several steps.
  • a mixture of a solid, porous carrier and a non-polar solvent is contacted with at least one organomagnesium composition of the formula where R and R' are the same or different C4-C12 alkyl groups, m and n are each 0, 1 or 2, providing that m + n equals the valence of Mg.
  • the mixture of the first step is contacted with at least one compound of the formula where R" is a C1-C10 alkyl group or a C1-C10 halogenated alkyl group.
  • the resulting mixture is then contacted with at least one transition metal compound soluble in the non-polar solvent.
  • the product of the above steps is dried and it is activated with dimethylaluminum chloride, a catalyst activator.
  • the resulting activated catalyst composition has high productivity in the polymerization of olefins, particularly alpha-olefins, good higher comonomer (i.e., C3-C10 alpha-olefin) incorporation properties, and it produces polymers having a substantially improved homogeneity of distribution of branches among the polymer molecules.
  • the invention is also directed to a supported catalyst composition
  • a supported catalyst composition comprising at least one organomagnesium composition of the formula where R, and R', m and n are the same as defined above, at least one compound of the formula where R" is also the same as defined above, at least one transition metal compound, and dimethylaluminum chloride.
  • the invention also provides a method of polymerizing at least one olefin, which comprises contacting the olefin under olefin polymerization conditions with a catalyst according to the invention.
  • the polymers prepared in the presence of the catalyst compositions of this invention are linear polyethylenes which are homopolymers of ethylene or copolymers of ethylene and higher alpha-olefins.
  • the polymers have relatively low values of crystalline melting points, thereby indicating a substantially improved homogeneity of distribution of branches among the polymer molecules, as compared to similar polymers prepared in the presence of previously-known catalyst compositions, e.g., those disclosed by in use US-A-4,849,389.
  • the polymers prepared with the catalyst compositions of this invention are especially suitable for the production of high strength films and injection molding applications.
  • Catalysts produced according to the present invention are described below in terms of the manner in which they are made.
  • the carrier materials are usually inorganic, solid, particulate porous materials which are inert to the other components of the catalyst composition and to the other active components of the reaction system. These carrier materials include such inorganic materials as oxides of silicon and/or aluminum.
  • the carrier materials are used in the form of dry powders having an average particle size of from about 1 micron to about 250 microns, preferably from about 10 microns to about 150 microns.
  • the carrier materials are also porous and have a surface area of at least about 3 square meters per gram, and preferably at least about 50 square meters per gram.
  • the carrier material should be dry, that is, free of absorbed water. Drying of the carrier material can be effected by heating at about 100 to about 1000°C and preferably at about 600°C.
  • the carrier When the carrier is silica, it is heated at a temperature of at least 200°C, preferably at about 200 to about 850°C, and most preferably at about 600°C.
  • the carrier material should have at least some active hydroxyl (OH) groups to produce the catalyst composition of this invention.
  • the carrier is silica which, prior to the use thereof in the first catalyst synthesis step, has been dehydrated by fluidizing with nitrogen and heating at about 600°C for about 16 hours to achieve a surface hydroxyl concentration of about 0.7 mmols/gm.
  • the silica is in the form of spherical particles, e.g., as obtained by a spray-drying process.
  • the carrier material is slurried in a non-polar solvent and the resulting slurry is contacted with at least one organomagnesium composition having the empirical formula (I).
  • the slurry of the carrier material in the solvent is prepared by introducing the carrier material into the solvent, preferably while stirring, and heating the mixture to about 25 to about 100°C, preferably about 40 to about 60°C. The slurry is then contacted with the aforementioned organomagnesium composition, while the heating is continued at the aforementioned temperature.
  • the organomagnesium composition has the empirical formula R m Mg R' n' where R and R' are the same or different C4-C12 alkyl groups, preferably C4-C10 alkyl groups, more preferably C4-C8 unsubstituted alkyl groups, and most preferably both R and R' are n-butyl groups; and m and n are each 0, 1 or 2, providing that m + n is equal to the valence of Mg.
  • Suitable non-polar solvents are materials in which all of the reactants used herein, i.e., the organomagnesium composition, the compound(s) of formula (II), the transition metal compounds and the halogenated alkyl aluminum compounds are at least partially soluble and which are liquid at reaction temperatures.
  • Preferred non-polar solvents are alkanes, such as hexane, n-heptane, octane, nonane, and decane, although a variety of other materials including cycloalkanes, such as cyclohexane, aromatics, such as benzene and ethylbenzene, can be employed.
  • the most preferred non-polar solvent is hexane.
  • the non-polar solvent Prior to use, the non-polar solvent should be purified, such as by percolation through silica gel and/or molecular sieves, to remove traces of water, oxygen, polar compounds, and other materials capable of adversely affecting catalyst activity.
  • the carrier drying temperature affects the number of sites on the carrier available for the organomagnesium composition - the higher the drying temperature the lower the number of sites.
  • the exact molar ratio of the organomagnesium composition to the hydroxyl groups will vary and must be determined on a case-by-case basis to assure that only such an amount of the organomagnesium composition is added to the solution which will be deposited onto the support without leaving any excess of the organomagnesium composition in the solution. Furthermore, it is believed that the molar amount of the organomagnesium composition deposited onto the support is greater than the molar content of the hydroxyl groups on the support.
  • the molar ratios given below are intended to serve only as an approximate guideline and the exact amount of the organomagnesium composition in this embodiment must be controlled by the functional limitation discussed above, i.e., it must not be greater than that which can be deposited onto the support.
  • the amount of the organomagnesium composition which is not greater than that deposited onto the support can be determined in any conventional manner, e.g., by adding the organomagnesium composition to the slurry of the carrier in the solvent, while stirring the slurry, until the organomagnesium composition is detected as a solution in the solvent.
  • the amount of the organomagnesium composition added to the slurry is such that the molar ratio of Mg to the hydroxyl groups (OH) on the solid carrier is about 1:1 to about 6:1, preferably about 2:1 to about 4:1, more preferably about 2.5:1 to about 3.5:1 and most preferably about 3:1, depending upon the temperature at which the carrier material was dried.
  • the organomagnesium composition dissolves in the non-polar solvent to form a solution.
  • organomagnesium composition which is in excess of that which will be deposited onto the support and then remove, e.g., by filtration and washing, any excess of the organomagnesium composition.
  • this alternative is less desirable than the most preferred embodiment described above.
  • the slurry is contacted with at least one compound of the formula (II) where R" is a C1-C10 alkyl group or a C1-C10 halogenated alkyl group; preferably R" is a C1-C10 alkyl group, more preferably a C1-C4 normal alkyl group or a C1-C4 halogenated normal alkyl group, and most preferably R" is an ethyl group.
  • the compound of formula (II) is preferably an alcohol and most preferably ethanol.
  • the amount of the compound of formula (II) used in this synthesis step is sufficient to convert substantially all of the magnesium alkyl (MgR or MgR') groups on the carrier to magnesium alkoxy (MgOR") groups.
  • the amount of the formula (II) compound added is such that substantially no excess thereof is present in the non-polar solvent after substantially all of the magnesium alkyl groups are converted to the magnesium alkoxy groups on the carrier to prevent the reaction of the formula (II) compound with the transition metal compound outside of the carrier.
  • This synthesis step is conducted at about 25 to about 65°C, preferably at about 30 to about 55°C, and most preferably at about 30 to about 40°C.
  • the slurry is contacted with at least one transition metal compound soluble in the non-polar solvent.
  • This synthesis step is conducted at about 25 to about 65°C, preferably at about 30 to about 55°C, and most preferably at about 30 to about 40°C.
  • the amount of the transition metal compound added is not greater than that which can be deposited onto the carrier.
  • the exact molar ratio of Mg to the transition metal and of the transition metal to the hydroxyl groups of the carrier will therefore vary (depending, e.g., on the carrier drying temperature) and must be determined on a case-by-case basis.
  • the amount of the transition metal compound is such that the molar ratio of the transition metal, derived from the transition metal compound, to the hydroxyl groups of the carrier is about 1:1 to about 2:1, preferably about 1.5:1 to about 2:1 and the molar ratio of Mg to the transition metal is about 1:1 to about 3:1, preferably about 2:1 to about 3:1.
  • These molar ratios produce a catalyst composition which produces resins having relatively narrow molecular weight distribution and improved branching homogeneity. As is known to those skilled in the art, such resins can be utilized to produce film or injection molding products.
  • Suitable transition metal compounds used herein are compounds of metals of Groups IVA, VA, VIA OR VIIIA of the Periodic Table of the Elements, as published by the Sargent-Welch Scientific Company, Catalog No. 5-18806, 1979, providing that such compounds are soluble in the non-polar solvents.
  • Non-limiting examples of such compounds are titanium and vanadium halides, e.g., titanium tetrachloride, TiC14, vanadium tetrachloride, VC14, vanadium oxytrichloride, VOC13, titanium and vanadium alkoxides, wherein the alkoxide moiety has a branched or unbranched alkyl radical of 1 to about 20 carbon atoms, preferably 1 to about 6 carbon atoms.
  • the preferred transition metal compounds are titanium compounds, preferably tetravalent titanium compounds.
  • the most preferred titanium compound is titanium tetrachloride. Mixtures of such transition metal compounds may also be used and generally no restrictions are imposed on the transition metal compounds which may be included. Any transition metal compound that may be used alone may also be used in conjunction with other transition metal compounds.
  • halogenated alkyl aluminum compound is added to the reaction slurry.
  • the halogenated alkyl aluminum compound has the formula: where R3 is a C1-C10 alkyl group, preferably a C1-C5 alkyl group, more preferably a C1-C4 normal alkyl group and most preferably R3 is an ethyl group; X is Cl, Br or I, preferably Cl or Br and most preferably Cl; and y is 1 or 2.
  • the halogenated alkyl aluminum compound is ethylaluminum dichloride (EADC) or diethylaluminum chloride (DEAC).
  • the amount of the halogenated alkyl aluminum compound added to the reaction mixture is such that the Al:transition metal (derived from the transition metal compound) molar ratio in the catalyst composition is about 0.1 to about 10, preferably about 0.5 to about 5 and most preferably about 1.0 to about 2.0. It will be apparent to those skilled in the art that mixtures of the halogenated alkyl aluminum compounds may also be used in this step of the alternative embodiment of the catalyst synthesis process.
  • the halogenated alkyl aluminum compounds are preferably added to the reaction slurry while it is stirred at about 25°C to about 65°C, preferably at about 30° to about 55°C, more preferably at about 30° to about 40°C and most preferably while the slurry is maintained under reflux conditions.
  • the amount of the halogenated alkyl aluminum compound used herein is not greater than that which can be deposited onto the carrier.
  • the exact molar ratio of Al:transition metal will vary (depending, e.g., on the carrier drying temperature), and must be determined on a case-by-case basis.
  • the resulting catalyst precursor of this alternative embodiment is that of US-A-4,833,111. Accordingly, the catalyst precursor of this embodiment comprises, in addition to the remaining ingredients of the catalyst composition of this invention, at least one halogenated alkyl aluminum compound of formula (III), defined above.
  • the compound of formula (II) is a chlorinated alcohol, i.e., R" is a chlorinated C2-C10 alkyl group, preferably a chlorinated C2-C4 normal alkyl group, more preferably a chlorinated C2-C4 normal alkyl group and most preferably a chlorinated ethyl group.
  • R" is a chlorinated C2-C10 alkyl group, preferably a chlorinated C2-C4 normal alkyl group, more preferably a chlorinated C2-C4 normal alkyl group and most preferably a chlorinated ethyl group.
  • the compound of formula (II) is 2,2,2-trichloroethanol.
  • chlorinated alcohol designates a C2-C10 alcohol having at least one of its hydrogens on the second (beta) or higher carbon atom replaced by chlorine.
  • alcohols having chlorine on the first (alpha) carbon atom of the alcohol are not suitable for use in this embodiment of the invention.
  • Carbon atoms of the alcohol are named in a conventional manner by naming the carbon most distant from the hydroxyl group (OH) as the alpha carbon, with the next carbon being beta carbon, etc.
  • chlorinated alcohols examples include 2-chloroethanol, 2,2-dicholoroethanol, 2,2,2-trichloroethanol, 2-chloro-propanol, 2,2-dichloro-propanol, 2,2,3-trichloro-propanol, 2,2,3,3-tetrachloro-propanol, 2-chloro- n -butanol, 2,3-dichloro- n -butanol, 2,3,4-trichloro- n -butanol, 2,3,4,4-tetrachloro- n -butanol, and 2,2,3,3,4,4-hexachloro- n -butanol.
  • the amount of the chlorinated alcohol used in this synthesis step of this alternative embodiment is sufficient to convert substantially all of the magnesium alkyl (MgR or MgR') groups on the carrier to magnesium alkoxy (MgOR") or magnesium chloride (Mg-Cl) groups.
  • the amount of the chlorinated alcohol added is such that substantially no excess thereof is present in the non-polar solvent after substantially all of the magnesium alkyl groups are converted to the magnesium alkoxy or magnesium-chloride groups on the carrier to prevent the reaction of the chlorinated alcohol of formula (II) with the transition metal compound outside of the carrier.
  • the amount of the chlorinated alcohol of formula (II) used herein is about 0.40 to about 3.0 mmols of the chlorinated alcohol per gram of dried silica.
  • This synthesis step is conducted at about 25 to about 65°C, preferably at about 30 to about 55°C, and most preferably at about 30 to about 40°C.
  • the catalyst precursor of this alternative embodiment is that of US-A-4954470.
  • the non-polar solvent is slowly removed, e.g., by distillation or evaporation.
  • the temperature at which the non-polar solvent is removed from the synthesis mixture affects the productivity of the resulting catalyst composition. Lower solvent removal temperatures produce catalyst compositions which are substantially more active than those produced with higher solvent removal temperatures. For this reason, it is preferred to remove the non-polar solvent at about 40 to about 65°C, preferably at about 45 to about 55°C and most preferably at about 50°C by drying, distillation or evaporation or any other conventional means.
  • DMAC dimethylaluminum chloride
  • the combination of the herein-described precursor with the DMAC activator produces an activated alpha-olefin polymerization catalyst composition which polymerizes olefins, particularly alpha-olefins, to polymers believed to have substantially improved distribution of branches among the polymer molecules.
  • the more uniform distribution of branches is manifested by the fact that the polymers made with the activated catalyst of this invention have crystalline melting points about 1-2°C lower than the polymers made with the same precursor but activated with trimethylaluminum.
  • the DMAC activator is used in an amount which is at least effective to promote the polymerization activity of the solid catalyst component of this invention.
  • the amount of the DMAC activator is sufficient to give an Al:transition metal molar ratio in the catalyst composition of about 2 to about 200, preferably about 10 to about 150, and most preferably about 20 to about 80.
  • the catalyst composition of this invention is produced by chemically impregnating the support with catalyst components sequentially added to the slurry of the carrier in the non-polar solvent. Therefore, all of the catalyst synthesis chemical ingredients (reagents) must be soluble in the non-polar solvent used in the synthesis. The order of addition of the reagents may also be important since the catalyst synthesis procedure is predicated on the chemical reaction between the chemical ingredients sequentially added to the non-polar solvent (a liquid) and the solid carrier material or a catalyst intermediate supported by such a material (a solid). Thus, the reaction is a solid-liquid reaction.
  • the catalyst synthesis procedure must be conducted in such a manner as to avoid the reaction of two or more reagents in the non-polar solvent to form a reaction product insoluble in the non-polar solvent outside of the solid catalyst support.
  • Such an insoluble reaction product would be incapable of reacting with the carrier or the catalyst intermediate and therefore would not be incorporated onto the solid support of the catalyst composition.
  • the catalyst precursors of the present invention are prepared in the substantial absence of water, oxygen, and other catalyst poisons.
  • Such catalyst poisons can be excluded during the catalyst preparation steps by any well known methods, e.g., by carrying out the preparation under an atmosphere of nitrogen, argon or other inert gas.
  • An inert gas purge can serve the dual purpose of excluding external contaminants during the preparation and removing undesirable reaction by-products resulting from the preparation of catalyst precursor. Purification of the non-polar solvent employed in the catalyst synthesis is also helpful in this regard.
  • the catalyst may be activated in situ by adding the DMAC activator and the precursor separately to the polymerization medium. It is also possible to combine the precursor and the activator before the introduction thereof into the polymerization medium, e.g., for up to about 2 hours prior to the introduction thereof into the polymerization medium at a temperature of from about -40 to about 100°C.
  • Alpha-olefins are polymerized with the catalysts prepared according to the present invention by any suitable process.
  • Such processes include polymerizations carried out in suspension, in solution or in the gas phase.
  • Gas phase polymerization reactions are preferred, e.g., those taking place in stirred bed reactors and, especially, fluidized bed reactors.
  • the molecular weight of the polymer may be controlled in a known manner, e.g., by using hydrogen. With the catalysts produced according to the present invention, molecular weight may be suitably controlled with hydrogen when the polymerization is carried out at relatively low temperatures, e.g., from about 30 to about 105°C. This control of molecular weight may be evidenced by a measurable change in melt index (I2) of the polymer produced.
  • the linear polyethylene polymers prepared in accordance with the present invention are homopolymers of ethylene or copolymers of ethylene with one or more C3-C10 alpha-olefins. Thus, copolymers having two monomeric units are possible as well as terpolymers having three monomeric units.
  • Such polymers include ethylene/propylene copolymers, ethylene/1-butene copolymers, ethylene/1-hexene copolymers, ethylene/1-octene copolymers, ethylene/4-methyl-1-pentene copolymers, ethylene/1-butene/1-hexene terpolymers, ethylene/propylene/1-hexene terpolymers and ethylene/propylene/1-butene terpolymers.
  • propylene When propylene is employed as a comonomer for copolymerization with ethylene, substantially more propylene is required to produce linear low density polyethylene polymer resins with required density for a particular application than 1-butene or higher olefins, used as comonomers, to produce comparable resins.
  • Ethylene/1-hexene is the most preferred copolymer.
  • linear polyethylene polymers produced in accordance with the present invention preferably contain at least about 80 percent by weight of ethylene units.
  • a particularly desirable method for producing linear low density polyethylene polymers according to the present invention is in a fluid bed reactor.
  • a reactor and means for operating it are described in US-A-4,011,382, US-A-4,302,566 and US-A-4,481,301.
  • the polymer produced in such a reactor contains the catalyst particles because the catalyst is not separated from the polymer.
  • Density ASTM D 1505--A plaque is made and conditioned for one hour at 100°C to approach equilibrium crystallinity. Measurement for density is then made in a density gradient column; reported as gms/cc.
  • MI Melt Index
  • I2 ASTM D-1238--Condition E--Measured at 190°C--reported as grams per 10 minutes.
  • High Load Melt Index (HLMI) I21: ASTM D-1238 --Condition F - Measured at 10.5 times the weight used in the Melt Index test, above.
  • Melt Flow Ratio (MFR) I21/I2 Crystalline Melting Point (T m ): Melting points of copolymers were measured by the Differential Scanning Calorimetry (DSC) method, at a heating rate of 2°C/min. Both unannealed and annealed samples were analyzed. Samples were annealed by heating the samples weighing about 10 mg to 150°C and cooling them to 40°C at a rate of 0.5°C/min.
  • DSC Differential Scanning Calorimetry
  • Comonomer content Comonomer contents of ethylene copolymers were measured by the infrared spectroscopic method, as described by T. E. Nowlin, Y. V. Kissin and K. P. Wagner, HIGH ACTIVITY ZIEGLER-NATTA CATALYST FOR THE PREPARATION OF ETHYLENE COPOLYMERS, Journal of Polymer Science: Part A: Polymer Chemistry, Volume 26, pages 755-764 (1988).
  • Crystallinity of ethylene copolymers was measured by the DSC method, from the areas under the melting curves. The heat of melting for 100% crystalline polyethylene was chosen as 283 Joule/g.
  • the resulting catalyst precursor contained 1.70 mmols of Mg/gram of the precursor, 0.91 mmols of Ti/gram of the precursor, and 2.87 mmols of Cl/gram of the precursor.
  • Example 1 The catalyst precursor of Example 1 was combined with triethylaluminum (TEAL) , trimethylaluminum (TMA) or dimethylaluminum chloride (DMAC) catalyst activators to produce ethylene/1-hexene copolymers. Typical was the polymerization of Example 5, carried out in the manner summarized below with the catalyst of Example 1.
  • TEAL triethylaluminum
  • TMA trimethylaluminum
  • DMAC dimethylaluminum chloride
  • Polymerization conditions were controlled to produce ethylene/1-hexene copolymers containing about 4 to about 5% mole of 1-hexene.
  • a 1.6 liter stainless steel autoclave previously heated to about 70°C under a purge of dry nitrogen, was filled with 560 mls of dry hexene, 190 mls of dry 1-hexene and 10 mls of dimethylaluminum chloride (25 wt% in hexane).
  • the reactor was closed, and hydrogen was introduced to raise the internal pressure to 40 psi.
  • the contents of the reactor were stirred at 900 rpm and the temperature was increased to about 80°C.
  • the reactor was filled with ethylene to a total pressure of about 180 psi and then 0.144 grams of Example 1 catalyst precursor, slurried in about 50 mls of hexane, was added to the reactor.
  • the reactor temperature was adjusted to 85°C and the reactor pressure was maintained with ethylene.
  • the polymerization was continued for 50 minutes. 95 grams of polyethylene were obtained.
  • the polymer contained 4.4 mole % of 1-hexene and it had the properties summarized in Table 1.
  • the data of Table 1 indicates that when the ethylene-hexene copolymers of equal composition are compared, the copolymers produced with the DMAC-activated precursor have significantly lower density, lower crystallinity, and lower melting points (both in the annealed and unannealed forms) than the copolymers produced with the TEAL- or TMAactivated precursors of Example 1. According to US-A-3,645,992, all these changes are indicative of a more homogeneous distribution of short chain branches among the polymer molecules in the copolymers produced with the DMAC- activated precursor.
  • the crystallizable component in any ethylene-olefin copolymer produced with a heterogeneous Ziegler-Natta catalyst can be separated into two fractions: a highly crystalline fraction (which determines the melting point of the copolymer) and a fraction of decreased crystallinity.
  • DSC analysis of the average of the ethylene/1-hexene copolymers of Examples 2-5 provides a means for an approximate estimation of the relative contents of these fractions. This information is presented in Table 2.
  • the data of Table 2 indicates that the copolymers produced with the catalyst of this invention have a lower fraction of highly crystalline material than the copolymers produced with the TEAL and TMA as catalyst activators, thereby indicating that the copolymers produced with the catalysts of this invention have an improved, more homogeneous branching distribution than the copolymers produced with the same precursors activated with TEAL or TMA.
  • Example 6 and 7 the polymerization process was conducted in substantially the same manner as in Examples 2-5, but process conditions were adjusted to produce ethylene/1-hexene copolymers containing about 3.8 mole of 1-hexene.
  • Tables 3 and 4 The results are summarized in Tables 3 and 4.
  • the data of Tables 2 and 4 indicates that LLDPE produced with the DMAC-activated catalyst not only has lower crystallinity (as shown in Tables 1 and 3), but its crystalline phase contains a lower fraction of a highly crystalline material.
  • lower melting points of the copolymers produced with the DMAC-activated catalyst (Tables 1 and 3) indicate that these highly crystalline fractions have a more branched structure.
  • the results are presented in Figure 1.
  • the upper curve of Figure 1 is based on melting points of the resins considered to be a commercial standard, produced with a catalyst described in EP-A-0 120 503, Example 1(b), partially activated in accordance with Examples 2(b) or 2(c) thereof, and activated in the polymerization process with TEAL.
  • the copolymers of the upper curve have a broad branching distribution, as indicated by insignificant changes in their crystalline melting points with the change in the 1-hexene content.
  • the lower curve gives melting points of narrow copolymer fractions of the polymers of EP-A-0120503, which have very narrow branching distribution (substantially homogeneous copolymers).
  • the fractionation was performed using the preparative TREF procedure (temperature-raising elution fractionation).
  • the crystalline melting points of the copolymers of the lower curve decrease very rapidly with the increase in the 1-hexene content, as indicated by the slope of the curve.
  • the branching distribution of a copolymer can be determined by measuring its crystalline melting point and its comonomer content.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
  • Polymerization Catalysts (AREA)
EP19900314182 1989-12-26 1990-12-21 Katalysator auf Träger für Olefinpolymerisation Expired - Lifetime EP0435627B1 (de)

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US45690589A 1989-12-26 1989-12-26
US456905 1989-12-26

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EP0435627A2 true EP0435627A2 (de) 1991-07-03
EP0435627A3 EP0435627A3 (en) 1992-01-02
EP0435627B1 EP0435627B1 (de) 1996-07-31

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JP (1) JPH04218506A (de)
AU (1) AU645531B2 (de)
CA (1) CA2033001C (de)
DE (1) DE69027979T2 (de)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0435557A2 (de) * 1989-12-26 1991-07-03 Mobil Oil Corporation Durch Dimethylaluminiumchlorid aktivierter Olefinpolymerisationskatalysator
EP0528558A1 (de) * 1991-08-06 1993-02-24 Mobil Oil Corporation Katalysatorzusammensetzung zur Herstellung von linearen Ethylen-Hexencopolymeren mit niedriger Dichte und daraus hergestellte Filme
WO1993019105A2 (en) * 1992-03-20 1993-09-30 The Dow Chemical Company Silica supported transition metal catalyst
US5258345A (en) * 1992-11-20 1993-11-02 Mobil Oil Corporation High-activity polyethylene catalysts
US5693583A (en) * 1991-06-10 1997-12-02 Mobil Oil Corporation High activity polyethylene catalysts which produce bimodal or trimodal product molecular weight distributions
US6172173B1 (en) 1991-01-18 2001-01-09 The Dow Chemical Company Silica supported transition metal catalyst
US6747113B1 (en) 1991-01-18 2004-06-08 The Dow Chemical Company Silica supported transition metal catalyst
EP0775163B2 (de) † 1994-08-12 2006-04-05 The Dow Chemical Company Katalysator auf träger für olefinpolymerisation
US7893180B2 (en) 1998-10-27 2011-02-22 Westlake Longview Corp. Process for the polymerization of olefins; novel polyethylenes, and films and articles produced therefrom

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4849389A (en) * 1988-01-14 1989-07-18 Mobil Oil Corporation Catalyst composition for polymerizing alpha-olefin polymers of narrow molecular weight distribution
EP0435557A2 (de) * 1989-12-26 1991-07-03 Mobil Oil Corporation Durch Dimethylaluminiumchlorid aktivierter Olefinpolymerisationskatalysator

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US4378304A (en) * 1981-06-03 1983-03-29 Chemplex Company Catalyst and methods
US4833111A (en) * 1988-01-14 1989-05-23 Mobil Oil Corporation Catalyst composition for polymerizing alpha-olefin polymers of narrow molecular weight distribution

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4849389A (en) * 1988-01-14 1989-07-18 Mobil Oil Corporation Catalyst composition for polymerizing alpha-olefin polymers of narrow molecular weight distribution
EP0435557A2 (de) * 1989-12-26 1991-07-03 Mobil Oil Corporation Durch Dimethylaluminiumchlorid aktivierter Olefinpolymerisationskatalysator

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
MACROMOLECULES. vol. 15, no. 3, 1982, EASTON US pages 831 - 834; A.ZAMBELLI: 'ISOTACTIC POLYMERIZATION OF PROPENE: STEREOREGULARITYOF THE INSERTION OF THE FIRST MONOMER UNIT AS A FINGERPRINT OFCATALYTIC ACTIVE SITE' *

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0435557A3 (en) * 1989-12-26 1992-01-08 Mobil Oil Corporation Dimethylaluminum chloride-activated olefin polymerisation catalyst composition
EP0435557A2 (de) * 1989-12-26 1991-07-03 Mobil Oil Corporation Durch Dimethylaluminiumchlorid aktivierter Olefinpolymerisationskatalysator
US6747113B1 (en) 1991-01-18 2004-06-08 The Dow Chemical Company Silica supported transition metal catalyst
US6172173B1 (en) 1991-01-18 2001-01-09 The Dow Chemical Company Silica supported transition metal catalyst
US5693583A (en) * 1991-06-10 1997-12-02 Mobil Oil Corporation High activity polyethylene catalysts which produce bimodal or trimodal product molecular weight distributions
EP0528558A1 (de) * 1991-08-06 1993-02-24 Mobil Oil Corporation Katalysatorzusammensetzung zur Herstellung von linearen Ethylen-Hexencopolymeren mit niedriger Dichte und daraus hergestellte Filme
WO1993019105A2 (en) * 1992-03-20 1993-09-30 The Dow Chemical Company Silica supported transition metal catalyst
WO1993019105A3 (en) * 1992-03-20 1993-11-11 Dow Chemical Co Silica supported transition metal catalyst
US5258345A (en) * 1992-11-20 1993-11-02 Mobil Oil Corporation High-activity polyethylene catalysts
EP0775163B2 (de) † 1994-08-12 2006-04-05 The Dow Chemical Company Katalysator auf träger für olefinpolymerisation
WO1998034724A1 (en) * 1997-02-11 1998-08-13 Mobil Oil Corporation Ziegler-natta catalyst for ethylene polymerization or copolymerization
EP0969925A1 (de) * 1997-02-11 2000-01-12 Mobil Oil Corporation Ziegler-natta-katalysator für die polymerisierung oder die kopolymerisierung von ethylen
AU723865B2 (en) * 1997-02-11 2000-09-07 Mobil Oil Corporation Ziegler-natta catalyst for ethylene polymerization or copolymerization
EP0969925A4 (de) * 1997-02-11 2001-11-07 Exxonmobil Oil Corp Ziegler-natta-katalysator für die polymerisierung oder die kopolymerisierung von ethylen
US7893180B2 (en) 1998-10-27 2011-02-22 Westlake Longview Corp. Process for the polymerization of olefins; novel polyethylenes, and films and articles produced therefrom

Also Published As

Publication number Publication date
AU645531B2 (en) 1994-01-20
AU6844090A (en) 1991-07-11
CA2033001A1 (en) 1991-06-27
CA2033001C (en) 2003-04-08
DE69027979T2 (de) 1996-11-28
EP0435627A3 (en) 1992-01-02
EP0435627B1 (de) 1996-07-31
DE69027979D1 (de) 1996-09-05
JPH04218506A (ja) 1992-08-10

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